I was messing around last night, figured I'd throw this picture up for anyone curious. A Giant Loop Coyote fits the KLR fairly well. The rear hooks just barely fit, I have the strap as long as it can go and had to pull them pretty tight. They are meant to hook on the fender, but I have the left side on this gusset looking part of the frame and the right where the helmet lock used to be. I may notch the fender later to get it to fit better, haven't decided if it's needed or not. The kicker barely works, but does. You need to angle your foot out some and kick with your heel. The lower straps need to be on the passanger peg bracket to angle the bag down. If they are on the frame like I do on my XR then the bag sits more flat and the kicker hits the bag.
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I realize I need the KLR 600 base manual, and the KLR 250 Supplement. I found that the KLR 600 appears to have been in production from '84-'90? I am wondering, would the manual of any particular year be preferable?

I realize I need the KLR 600 base manual, and the KLR 250 Supplement. I found that the KLR 600 appears to have been in production from '84-'90? I am wondering, would the manual of any particular year be preferable?

Not preferable, IMHO, because referrals in the KLR250 supplement are referred to the KLR600 base manual.

You could probably interpolate some yourself and "get by" with a KLR650 manual, either Kawasaki publication or Clymer's, but . . . wouldn't say the technique "preferable" to a KLR600 manual; YMMV!

Finally got my basket case twofiddy running. The 1.0mm over Wiseco piston worked great....until the slighly ganked cam chain tensioner cap screw gave way and started burping oil. Also noticed that the handlebars took some hits, so that's on the list too.

Got my bash plate installed, finished setting the valves and got her put back together. Wired in phone, gps, and Trail Tech computer on a switch. So far so good.

Then I pulled the rear suspension links and pins to swap for lowering links and was disappointed to find rusty pin surfaces and rusty pins where the links were in contact with them. I tried polishing out with steel wool, but there is very shallow pitting.

After seeing that the pins rotate on roller bearings, and those surfaces were clean and undamaged, I have come to the conclusion that unless there is a loose fit, the rusted links and pins are not a problem.

I bought a well-maintained '89 KLR250 from another member here but have decided I miss having a XT225 too much. This is advance notice as I need to sort out a front brake problem first. This is the last year of the 28 hp model. After that you got 23 hp. Some of you may remember this bike and the owner. I will probably be asking $1000. for it and a box of spares. More pics available on request.